Wilsons Sandbox

I looked in the archives but couldn t find an answer to my problem. My KLR A15 s clutch is sticking when cold. If the bike is in first gear with the engine off and I pull the clutch lever all the way to the grip, I can not move the bike. It has to be in neutral. If I hit the starter button with the bike in first and the clutch pulled in, the bike makes a small lurch forward for about 4 inches then continues to turn over and start. If I start the bike in neutral and then pull in the clutch and shift into first the bike lurches forward a little. With the bike in neutral, clutch lever released and the engine running the bike does not creep forward even when cold. This bike only has 122 miles on it. It didn t do this when new. I replaced the clutch lever because I bent the original one. The problem showed up after I installed the new clutch lever. I adjusted it to what the manual suggests. 2 mm and 15 mm end play. I reinstalled the old lever but the problem is still there. Is there some special trick to adjust the clutch lever? I didn t do anything to the bike accept change the bent clutch lever. same oil that was in it 122 miles ago _________________________________________________________________________ Get Your Private, Free E-mail from MSN Hotmail at http://www.hotmail.com Share information about yourself, create your own public profile at http://profiles.msn.com

I've seen this before & the cause was a lever that seemed to fit properly, but was not an exact replacement. The difference in the 2 levers was in the location of the pivot hole where the clutch cable end is inserted into the lever. If this slot is closer to the pivot bolt hole in the lever than it should be, you won't get the same amount (length) of pull when you dis-engage the clutch. Kawi's spec is for 10-15mm free play at the ball end. Try the 10mm setting if your old & new levers are identical. Just be sure that there is free play at the pivot bolt end of the lever when your KLR is warmed up. BTW, do you go by Squishy? Squish? Are you related to Sasquatch? Professor A9 Federal Way, WA. [USA] ++++++++++++++++++++++++++++++++++++++++++++ --- "The Squasher" wrote:

> I looked in the archives but couldn't find an answer to my

problem. My KLR A15's clutch is sticking when cold. If the bike is in first gear with the engine off and I pull the clutch lever all the way to the grip, I can not move the bike. It has to be in neutral. If I hit the starter button with the bike in first and the clutch pulled in, the bike makes a small lurch forward for about 4 inches then continues to turn over and start. If I start the bike in neutral and then pull in the clutch and shift into first the bike lurches forward a little. With the bike in neutral, clutch lever released and the engine running the bike does not creep forward even when cold. This bike only has 122 miles on it. It didn't do this when new. I replaced the clutch lever because I bent the original one. The problem showed up after I installed the new clutch lever. I adjusted it to what the manual suggests. 2 mm and 15 mm end play. I reinstalled the old lever but the problem is still there. Is there some special trick to adjust the clutch lever? I didn't do anything to the bike accept change the bent clutch lever. same oil that was in it 122 miles ago

I have both the stock and aftermarket levers. Both ack the same, although the location of the pivot holes are different. The only other thing I can think of is that when the bike was new the clutch plates weren't smooth so they didn't stick together when cold. Now after 100+ miles the plates had a chance to wear (set) in and now they are sticking. It's just funny how it happened around the same time I changed my clutch lever. Is there any one out there with a stock A15 with over 200 miles that show signs of a sticking clutch when cold. Thanks Craig A15 As for what is Squasher. It's my dogs name.

>From: "Jim Hyman" >To: "The Squasher" >Subject: Re: Clutch lever adjustment???? >Date: Wed, 06 Sep 2000 09:06:42 -0000 > >I've seen this before & the cause was a lever that seemed to >fit properly, but was not an exact replacement. The difference >in the 2 levers was in the location of the pivot hole where the >clutch cable end is inserted into the lever. If this slot is >closer to the pivot bolt hole in the lever than it should be, >you won't get the same amount (length) of pull when you >dis-engage the clutch. > >Kawi's spec is for 10-15mm free play at the ball end. Try the >10mm setting if your old & new levers are identical. Just be >sure that there is free play at the pivot bolt end of the lever >when your KLR is warmed up. > >BTW, do you go by Squishy? Squish? Are you related to Sasquatch? > >Professor A9 Federal Way, WA. [USA] > >++++++++++++++++++++++++++++++++++++++++++++

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